Aircraft Maintenance Manual (AMM) EC135

Rotor Brake System - Inspection

EFFECTIVITY ALL

6-1 Inspection - Rotor Brake System

A. References:

INTRODUCTION
63-51-00, 1-1 . . . . . . . . . . . . . . . . . . . Troubleshooting - Rotor Brake System
63-51-00, 4-1 . . . . . . . . . . . . . . . . . . . Removal / Installation - Brake Caliper
63-51-00, 4-4 . . . . . . . . . . . . . . . . . . . Removal / Installation - Brake Disk
63-51-00, 4-8 . . . . . . . . . . . . . . . . . . . Removal / Installation - Lever
63-51-00, 5-1 . . . . . . . . . . . . . . . . . . . Functional Test - Indicating System
63-51-00, 5-3 . . . . . . . . . . . . . . . . . . . Freedom of Movement Check - Slideway of Rotor Brake
Support
63-51-00, 5-5 . . . . . . . . . . . . . . . . . . . Leakage Test - Rotor Brake Hydraulic System
63-51-00, 7-1 . . . . . . . . . . . . . . . . . . . Cleaning - Brake Caliper
63-51-00, 8-1 . . . . . . . . . . . . . . . . . . . Replacement - Brake Linings

B. Special Tools:

None

C. Consumable Materials:

None

D. Routine Replacement Parts:

None

E. Procedure:

WARNING INSPECTION TASKS ARE NOT TO BE PERFORMED IMMEDIATELY

AFTER ACTUATION OF THE ROTOR BRAKE SYSTEM IN ORDER TO
PREVENT HOT COMPONENTS FROM CAUSING INJURIES.

IF THE ROTOR BRAKE SYSTEM IS ACTUATED WITH A DEFECTIVE

BRAKE DISK, IT IS NOT POSSIBLE TO GUARANTEE OPERATIONAL
SAFETY AS THERE MAY BE CONSEQUENTIAL DAMAGE TO THE TAIL
ROTOR DRIVE.

CAUTION WHEN HANDLING "CRITICAL PARTS ( CP)" AND "IMPORTANT PARTS ( IP)"
THE PROCEDURE ACC. TO (INTRODUCTION) IS TO BE OBSERVED.

NOTE For accomplishment of this inspection the LH transmission fairing must be

removed.

EFFECTIVITY Brake disk P/N L635M1025229

Configuration code : 000 63-51-00, 6-1 Page 601

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 Aircraft Maintenance Manual (AMM) EC135

(1) Accomplish a visual inspection of the whole surface on both sides of the brake disk for
cracks and local heat spots (refer to Figure 601):

(a) If cracks were found, notify ECD customer service and replace the brake disk
before the next flight (63-51-00, 4-4).

(b) If clearly visible hot spots were found:

- the rotor brake system must not be used until the brake disk is replaced,
- the rotor brake system must be shut down i.a.w. step (3),
- the brake disk must be replaced before the rotor brake system is used again
(63-51-00, 4-4).
Typical heat spots are localised tempering colours around a bare metal, coloured
homogeneous core zone.

In addition to the local heat spots, it may be possible to feel dents or bulges in
their proximity on the outer circumference of the brake disk, refer to step (2).

(2) Examine the outer circumference of the brake disk for dents, bulges, faults and waviness
(refer to Figure 601). To do so:

(a) Clean the outer circumference of the brake disk.

(b) Rotate the tail rotor drive shaft and simultaneously place a finger on the outer
circumference of the rotating brake disk to feel whether dents, bulges, faults and
waviness are present.

(c) If one of the above damage symptoms was found:

- the rotor brake system must not be used until the brake disk is replaced,
- the rotor brake system must be shut down i.a.w. step (3),
- the brake disk must be replaced before the rotor brake system is used again
(63-51-00, 4-4).

(3) If damage is present i.a.w step (1) and/or step (2), before the brake disk is replaced,
the rotor brake system must be shut down and identified as follows:

(a) Remove attachment hardware from between the damper and lever (63-51-00, 4-8).

(b) For the period that the rotor brake system is shut down, affix placard (1) over the
old placard (3) on the rotor brake lever (2, Figure 602) i.a.w. Figure 602.

EFFECTIVITY Brake disks P/N 08.4654.10 and 08.4654.30

(4) Inspect the brake disk for deformation and cracks. If the thickness of the brake disk has
been reduced by wear to less than 5 mm (0.197 in), or there are cracks or deformation,
replace the brake disk (63-51-00, 4-4).

EFFECTIVITY All

(5) Inspect the brake disk for wear. If the thickness of the brake disk has been reduced by
wear to less than 5 mm (0.197 in), replace the brake disk (63-51-00, 4-4).

(6) Examine brake linings for wear and damage.

NOTE The depth of a vertical groove in the brake lining indicates the
residual usable thickness.

Configuration code : 000 63-51-00, 6-1 Page 602

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 Aircraft Maintenance Manual (AMM) EC135

(a) Inspect brake linings for wear by looking through the upper opening in the brake
caliper. If the brake lining is worn to the extent that the groove is no longer visible,
it must be replaced (63-51-00, 8-1).

(b) Replace damaged (chipped) brake linings (63-51-00, 8-1).

(7) Inspect slideway of rotor brake support for free movement (63-51-00, 5-3).

(8) Accomplish a visual inspection of brake fluid reservoir, brake cylinder, brake caliper,
connecting hose, hose line and associated connections for leakage. Perform a leakage
test on the rotor brake hydraulic system (63-51-00, 5-5).

(9) Accomplish a visual inspection of brake caliper and brake piston for contamination and
clean, if necessary (63-51-00, 7-1).

(10) Perform a functional test on rotor brake indicating system (63-51-00, 5-1).

(11) Inspect brake lever for ease of movement. If lever binds, perform troubleshooting
(63-51-00, 1-1).

(12) Inspect braking system components for tight installation and tighten loose parts, as
necessary.

NOTE Only accomplish step (13) if the respective components have already been
removed.

(13) Inspect attachment hardware of the rotor brake system and close-tolerance bolt IP that
joins the lever with the brake cylinder (63-51-00, 4-8) for damage. Discard damaged
hardware or close-tolerance bolt IP.

Configuration code : 000 63-51-00, 6-1 Page 603

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 Aircraft Maintenance Manual (AMM) EC135

Possible Damage - Brake Disk P/N L635M1025 229

Figure 601

Configuration code : 000 63-51-00, 6-1 Page 604

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 Aircraft Maintenance Manual (AMM) EC135

Identification when Shut Down - Rotor Brake System

Figure 602

Configuration code : 000 63-51-00, 6-1 Page 605

2009.11.16